When you think of painting, the first thing that probably comes to mind is liquid paint; a 40,000-year-old substance that stretches back as far as cavemen. But in more recent times, powder coating has taken over as a hugely efficient alternative.

This post lists our top fifteen reasons why powder coating is becoming the preferred process for most industrial applications. Ercon is proud to be one of the leading powder coating providers in the West Midlands, located within easy reach of Wolverhampton, Birmingham and Coventry.

Ercon Powder Coating Project

One of our powder coating projects

Powder Coating…

Creates Less Waste: During the powder coating process, any powder that doesn’t adhere to the product falls into a collection hopper, from which it is sieved and re-used to minimise waste.  Any cured waste powder that is left over after this is not hazardous and can be land-filled.  Sometimes, excess powder coating emulsifies in water and can be drained away.  Meanwhile, liquid coating creates hazardous waste that is costly to dispose of and damaging to the environment.

Generates Lower Energy Costs: While no energy is required to evaporate solvents during powder coating processes, liquid coating forms a film around the substrate, from which around 50% of the solvents evaporate and are released into the atmosphere.

Generates Lower Training Costs: Training for powder coaters is quicker and easier than the necessary training for liquid coatings.  This is because no solvents or catalysts are used in powder coating processes, though the results are flawless.

Generates Lower Set-Up And Labour Costs: Powder coating materials are shipped ready to use.  Unlike liquid coating, they don’t need to be mixed with solvents or catalysts and are easy to apply.

Uses Equipment That Is Easier To Clean: The majority of cleaning is carried out using a vacuum.  Though leftover powder is re-cycled, any residual powder in a hose or hopper is easily blown to the extraction point of the booth using compressed air.

Is Environmentally Friendly: As no powder escapes into the atmosphere, powder coating processes don’t have a negative impact on the environment.  Powder-coating processes are dry and solvent-free, meaning that minimal toxic compounds are released.  On the other hand, liquid coating uses volatile solvents to provide coverage and flow.

Reduces Fire Risks: Unlike liquid coating, there are no solvents involved in powder coating processes, reducing flammable substances.  The lack of solvents reduces costs of statutory safety features for plants and insurance premiums.

Reduces Hazards: Powder coating is far better for the health of operators than liquid coating processes.  No solvents mean no nose, mouth or throat irritation.

Is Time Efficient: Unlike liquid coating, powder coating doesn’t require flash-off periods.  The curing process only lasts around twenty minutes, whereas liquid coated products can take days to cure.

Allows Controlled Thickness: Each component is powder coated to specification and can be re-dipped to meet your desired thickness. While cost increases with thickness, a single layer of powder coating can produce a depth of 2-4ml, whereas a single layer of liquid coating can only produce a depth of up to 1.2ml.  One layer of powder coating is often equivalent to multiple layers of liquid coating.

Is Available In Limitless Colours And Textures: Choose from Ercon’s RAL chart of extensive colours to pick the ideal shade for your product.  Our finishes can also be tailored for a range of textures, whether you prefer sparkle, metallic, hammer, antique, texture or spatter.

Has A High Utilisation Efficiency: Powder coating provides a finish with a utilisation efficiency of 90-95%.  Meanwhile, liquid coatings have a utilisation efficiency of around 35%.  This is because while powder coating overspray can be re-used, liquid coating overspray cannot.

Doesn’t Require Thinning: Most liquid coatings require thinning before application, which can be costly in terms of labour and materials.  This is not necessary for powder coating processes.

Minimises Air And Water-Related Problems: Powder coating is a dry process, so air-and-water-associated issues, such as sagging, running and contamination, are far less likely to occur than they are during liquid coating processes.  This also means that more parts can be coated automatically, saving time and costs.

Enables Precise Application And Even Finish: Powder coating enables a more precise application than liquid coating processes due to the curing phase.  Powder-coated parts are cured evenly in a curing oven to create a smooth finish without the spray spots that are common in liquid coating.  Powder-coated items tend to have fewer appearance differences than liquid-coated items, especially in terms of horizontally coated surfaces vs. vertically coated surfaces.